Dreaded HID failure - 'easy' fix and 'less easy' fix aren't easy at all

I have the dreaded intermittent loss of headlights with no warning. My diagnosis has confirmed that I have failing HID lamps and that I am beyond coverage by Toyota or the dealer. I have bought replacement (Philips DR4) lamps and have tried to replace them.

The first time, I tried to replace the driver's side by removing the fuse panel cover and relays, but I could not get the round, rear cover off the headlight assembly.

The second time, I tried to un-attach the top of the bumper to remove the headlight assembly, but I was foiled because the two philips-head screws holding the rubber bumpers and the top of the airfoil to the radiator frame were frozen solid. I have tried to PB-Blast them, but no luck so far. I am considering cutting them off and drilling out the remaining screw body, but I am afraid I can't get replacements. Besides, I really don't don't want to make this a bigger job than it already is.

Any recommendations?

 

Updated profile (Auburn, NH)

Even if I could have gotten get the cover off w/o headlight asm removal, I was afraid of exactly what happened to you. So, I figured it was best to pull the headlight asm out via a premeditated plan, rather than out of necessity. I am still stuck, however, until I get the two phillips head screws out (preferred) or only the rear covers off (not preferred).

 

As I noted in the OP, I tried to remove the headlight asm but the two philips head screws are fused solid.

Thanks for the tip on the ballast.

 

All good tips, but they're the philips head screws that do double duty holding down the top of the bumper asm and holding the rubber stops for the front lip of the hood (reference 1:37 in the luscious garage youtube video). This means the screw heads are buried in the rubber bumper 'volcano' so I can't use a socket or grab the head with vice grips.

 

Potentially very good news. Went to the dealer to get replacement bumpers and screws in case they had to be cut off and replaced. While there, the Parts guy suggested talking to Service. Service charges $30 labor to replace bulbs. They know the job "requires" taking off the bumper, but they can't justify the outrageous labor charge for a bulb change. Either they have a conscience, or they do it the quick way (no bumper removal, whatsoever). Either way, it's worth $30 not to deal with the stuck plastic cover or the rusted screws.

 

Dealer confirmed that they will install my bulbs (OEM Philips), but not warranty the work. I can deal with that since they probably wouldn't offer much of a warranty anyway.